1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Rev 03 2012 06 26 Re-Activated Used for Exterior lighting V. Cerato, NA 2012 05 21 N Status No usage or replacement N. Benipal, NA 1995 12 07 Activated J. FauntControlled document at www.MATS Copyright 2012, Ford Global Technologies, LLC Page
2、1 of 10 CLEAR TOPCOAT, UV CURABLE, ABRASION RESISTANT, WSS-M80J6-A TRANSPARENT PLASTIC PARTS 1. SCOPE The material defined by this specification is a clear UV stabilized, UV curable coating. 2. APPLICATION This specification was released originally to describe properties necessary for a clear protec
3、tive coating for polycarbonate headlamp lens. Prior to approval to this specification the coating will have to meet any additional requirements listed on the Engineering Drawing deemed necessary to produce quality parts, and sufficient pilot and production trials to confirm the acceptable manufactur
4、ing window defined by this specification. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.3 COMPOSITION Ford Motor Company, at its option, may cond
5、uct infrared spectroscopy (IR), emission spectroscopy (ES), pyrolitic gas chromotography (PGC), and thermogravimetric analysis (TGA) of material/parts supplied to this specification. The spectra established for initial approval shall constitute the reference standard and shall be kept on file at the
6、 designated material laboratory. All samples shall produce spectra that correspond to the reference standard when tested under the same conditions as those specified on the master spectrum. 3.3.1 Coating The coating shall not contain any commercial substance(s) known to attack polycarbonate. Consult
7、 the appropriate material supplier for published lists of these materials. The supplier will furnish the range of humidities under which the coating can be applied and cured without any evidence of blush. 3.3.2 Specific Composition The supplier will furnish the specific composition of the formulatio
8、n upon request. ENGINEERING MATERIAL SPECIFICATIONWSS-M80J6-A Copyright 2012, Ford Global Technologies, LLC Page 2 of 10 3.4 PHYSICAL PROPERTIES 3.4.1 Viscosity, Package Initial production (ASTM D 2196, Brookfield LVT batch +/- 10% with UL adaptor at 60 RPM) 3.4.2 Non-Volatile, min Initial productio
9、n (FLTM BI 102-06) batch +/- 5 % 3.4.3 Volume Non-Volatile at application viscosity, min (EPA Method 24) 3.5 PREPARATION OF TEST PANELS 3.5.1 Panels Unless otherwise specified, 2.5 - 4.0 mm thick approved injection molded headlamp lens grade clear polycarbonate (except for para 3.8.1), at least 75 m
10、m long and representative of production material. The process used to clean the polycarbonate prior to painting shall be described in detail. 3.5.2 Primer If required, apply, flash, and cure to manufacturers instructions 3.5.3 Clear Topcoat For para 3.6 and para 3.7.1 - 3.7.6, apply the coating at t
11、he conditions specified for Trial 29 in Table 1. For para 3.7.7 - 3.7.10, apply the coating at the conditions specified by the experimental design in Table 1. For para 3.8.1 - 3.8.3, apply the coating at the conditions specified by the experimental design in Table 2. A Zeiss MCS Diode Array Spectrom
12、eter is recommended to measure coating thickness. A surface profilometer or a mutually agreed upon method can be used in lieu of the Zeiss instrument. 3.6 APPEARANCE 3.6.1 Color, max Clear, Yellowness (ASTM D 1925) Index, YI 1.00 3.6.2 Gloss 60 (FLTM BI 110-01) Not more than a 10% decrease in gloss
13、relative to the uncoated plastic. 3.6.3 Clarity Sample three (ASTM D 1003) locations Haze may not increase by more than 0.5% average from the uncoated plastic. Luminous transmittance may not decrease by more than 0.5% average from the uncoated plastic. 3.6.4 General The coating shall bake out to a p
14、resentable, serviceable film showing no craters, pinholes, seediness, abnormal roughness or excessive metallic mottling. ENGINEERING MATERIAL SPECIFICATIONWSS-M80J6-A Copyright 2012, Ford Global Technologies, LLC Page 3 of 10 3.7 FILM PROPERTIES Use the experimental design given in Table 1 for para
15、3.7.7 through 3.7.10, and Table 2 for para 3.8.1 through 3.8.3. The process window defined by acceptable results for para 3.7.7 through 3.7.10 will constitute the Initial Acceptable Process Window. In reference to Table 1 for uv-curable paints, the supplier shall determine uv intensity according to
16、the following: i. For paint requiring focused uv lamp conditions, use maximum (peak) intensity. ii For paint requiring defocused, collimated, or other uv lamp conditions, use average intensity (see Figure 1 for definition of how to calculate and report average intensity). Record and report the follo
17、wing parameters (as applicable): conveyor speed, uv lamp type, uv lamp to part distance(s) and configuration(s), uv lamp focal length(s), relative humidity(ies), part (panel) temperature during cure, flash hot air temperature, flash lamp power, flash lamp to part distance(s), flash lamp configuratio
18、n, dwell times and temperature(s), and a full EIT Power Puck trace for each run including uv doses, uv intensities, part temperatures, and air temperatures. For thermal cure systems, a Datapaq, or similar instrument can be used to record part and air temperatures. Measure film builds at the same pan
19、el location(s) that the performance measurements are taken. 3.7.1 Abrasion Resistance, max All 5 panels: 7% (FLTM BN 108-02, Taber increase in haze Abrader, CS-10 wheel, 500 g load, 300 cycles, 5 panels) 3.7.2 Adhesion Fig. 4b or better (ASTM D 3359, Method B, 5 panels) Use 3M # 898 tape. 3.7.3 Ther
20、mal Shock Resistance (FLTM BI 107-05) The coating shall exhibit no blistering. Direct the steam blast along the entire length of each arm of the “X“ in a continuous motion for the 30 sec test period. 3.7.4 Resistance to Water and Soap Spotting (FLTM BI 113-01) Discoloration, max None ENGINEERING MAT
21、ERIAL SPECIFICATIONWSS-M80J6-A Copyright 2012, Ford Global Technologies, LLC Page 4 of 10 3.7.5 Resistance to Acid Spotting (FLTM BI 113-02) Discoloration, max None Gloss, no more than a 10% loss from value before exposure. See para 3.6.2. 3.7.6 Chemical Resistance (48 h at 23 +/- 2 C) Test Fluids:
22、1. Motor Oil 5W30 type SF (API), Ford Service Part Number X0-5W-30-QSP. 2. Tar Remover (petroleum base), Ford Service Part Number B7A-19520-A. 3. Windshield Washer Fluid, Methanol Base, ESB-M8B15-B, dilute 1:1 with distilled water for test. 4. Antifreeze, Ford Service Part Number E2FZ-19549-AA, dilu
23、te 1:1 with distilled water for test. 5. Reference Fuel D ASTM 471. Test Procedure: Wipe the entire coated surface of the panel with a 150 mm square soft cotton cloth (folded into a 75 mm square) that has been immersed in a container containing 60 mL of one of the chemicals listed in this test metho
24、d. Hold the cloth by one corner allowing the excess liquid drip. When the cloth has stopped dripping, wipe a test panel as follows: One back and forth wipe in the horizontal direction for the bottom, middle and upper surface. Store the panel for 48 h in an environment maintained at 23 +/- 2 C and a
25、relative humidity of 50 +/- 10%. Repeat this procedure for the remaining chemicals. After 48 h clean each panel with a clean soft cloth. Inspect the panel without magnification for rating. Test Acceptance Criteria: The panel surface shall not exhibit any surface deterioration, coating delamination,
26、substrate or coating cracking or color pick up. 3.7.7 Water Immersion Resistance, min 240 h (FLTM BI 104-01) Test Method: Paint and test 3 panels per trial number. Immerse panels for 240 h in distilled or deionized water maintained at 60 +/- 1 C. Remove panels from the water, and dry the scribed wit
27、h a paper towel, cloth or air pressure. Scribe panels within 5 minutes of removal from the water, and immediately perform an adhesion test per ASTM D 3359, Method B, with 13 cm2of 3M 898-2 tape. After the tape pull, abrade the surface with #0000 steel wool to highlight the areas of loss of adhesion.
28、 The following conditions shall be a basis for rejection. 1. 3B, 2B, 1B, or 0B performance as described in ASTM D 3359. 2. Evidence of loss of adhesion of the coating. ENGINEERING MATERIAL SPECIFICATIONWSS-M80J6-A Copyright 2012, Ford Global Technologies, LLC Page 5 of 10 3.7.7.1 Haze After Water Im
29、mersion, max 5% increase from (ASTM D 1003) coated plastic Test Method: Paint and test three panels per trial number. Remove panels from the water, and dry the scribed area with a paper towel, cloth or air pressure. Measure haze within 5 minutes of removal from the water immersion bath at three equa
30、lly spaced intervals along the center of the long axis of the panel. Report all three readings and the average of the three readings. The average increase of the three readings must be less than 5%. Note any visual haze formation in addition to the haze readings. The following is an additional basis
31、 for rejection. 1. No visible increase in haze may be noted at panel locations in excess of 6.5 mm from the panel periphery. Ford may, at its discretion, require that actual parts meet this requirement at Ford specified production process conditions. 3.7.8 Initial Ultraviolet Light Absorbance on Qua
32、rtz (FLTM AI 103-02, Method A) Use Method A with the following modifications: The quartz slide may be a 1 in. x 3 in. x 1 mm microscope slide. Step 2. Apply and process coating with conventional equipment. Step 3. Delete Step 4. Delete Step 5. Note the wavelength and absorbance of the maximum absorb
33、ance. If the absorbance is 3.0, use a neutral density filter of value 2.0 in the reference side of the spectrophotometer. Provide to Ford the absorption spectra and the neutral density spectrum, if applicable. 3.7.9 Initial Ultraviolet Light Absorbance on Plastic Panel(s) (FLTM AI 103-02, Method B)
34、Use Method B with the following changes: Only initial ultraviolet light absorbance is to be measured. No panels should be prepared for either Florida or weatherometer exposure. Step 2. Delete Step 15. Provide to Ford the absorption spectra, the weight of the sampled film, and the abs/conc. ENGINEERI
35、NG MATERIAL SPECIFICATIONWSS-M80J6-A Copyright 2012, Ford Global Technologies, LLC Page 6 of 10 3.7.10 Thermal Cycling Panels should be subjected to 15 consecutive repetitions of the following cycle: 16 hours humidity at 37 +/- 2 C and 95% minimum relative humidity. 3 hours at - 30 +/- 2 C. 1 hour r
36、ecovery at 25 +/- 2 C at 50% relative humidity. 3 hours at 110 +/- 2 C. 1 hour recovery at 25 +/- 2 C at 50% relative humidity. The following conditions shall be basis for rejection: 1. Any evidence of blistering or dulling. 2. Evidence of loss of adhesion. 3.8 WEATHERING REQUIREMENTS Coat and proce
37、ss plastic panels per Table 2. Expose the panels as follows: 3.8.1 Ultraviolet Light Absorber Loss Rate Coat and process clear polycarbonate, GE Plastics Lexan Resin 141, color 111, 0.0625 inch thick panels per Table 2. Measure initial ultraviolet absorbance spectrum from 450 nm to 250 nm. Perform a
38、ccelerated weathering per SAE J1960 with the following modification: Use type S borosilicate inner and outer filters, 0.55 W/m2irradiance intensity. Measure and record ultraviolet absorbance spectra at the same spot on the test plaque at the following exposure intervals: 250, 500, 750, 1000, 1500, a
39、nd 2000. Record and report the absorbance spectra, and the ultraviolet light absorber loss rate at the wavelength of the absorber maximum as a function of exposure. On an identical set of panels, perform and report the results of the adhesion test (ASTM D 3359, Method B, 13 cm2of 3M 898-2 tape) at e
40、ach exposure interval. In addition, perform and report the results of the following measurements at each exposure interval: haze (ASTM D 1003), and yellowing (ASTM D 1925) and visual assessment of any microcracking. Coat five polycarbonate panels, of the same polycarbonate type as lens products, wit
41、h the hardcoat minus any uvabsorbers, and process under the conditions of Trial 13 in Table 2. Measure initial yellow index (ASTM D 1925), haze (ASTM D 1003), and perform an adhesion test per ASTM D 3359, Method B, with 13 cm2of 3M 898-2 tape. After the tape pull, abrade the surface with #0000 steel
42、 wool to highlight the areas of loss of adhesion. Perform accelerated weathering per SAE J 1960 with the following modifications: type S borosilicate inner and outer filters, and 0.55 W/m2irradiance intensity. Measure and record yellow index, haze, and adhesion at the following intervals: 250, 500,
43、750, 1000, 1500, and 2000 hours, and at intervals of 500 hours thereafter until the coating or the coating interface has lost integrity, yellow index is in excess of 15, or haze is in excess of 20%. ENGINEERING MATERIAL SPECIFICATIONWSS-M80J6-A Copyright 2012, Ford Global Technologies, LLC Page 7 of
44、 10 Use an uncoated GE Plastics Lexan Resin 141, color 111, panel as control; measure initial and exposed ultraviolet absorbance spectra from 450 nm to 250 nm at 250, 500, 750, 1000, 1500, and 2000 hours. The uv-absorber depletion rate, the initial coating absorbance, and the results from the contro
45、ls will help predict the coating useful lifetime.* Predicted useful lifetime will be used to provide conditional approval pending the results of para 3.8.3, and subsequently, para 3.8.2. The results from para 3.8.3 will take precedence over predicted useful lifetime. * Per model described in: J. E.
46、Pickett and J. E. Moore, Polymer Degradation and Stability, 42, 231, 1993. 3.8.2 Florida Exposure 12, 24, 36, 48, 60, and 84 months (SAE J 576) at 45 direct facing south 60 month exposure must meet acceptance criteria defined in para 3.8.3 3.8.3 Accelerated Weathering Xenon Arc Apparatus 1000, 2000,
47、 4000, (SAE J1960 with the following 6000, 7200 and modification: Use type S borosilicate 10,000 hours inner and outer filters, 0.55 W/m2irradiance intensity) Condition for acceptance: 7200 hours xenon arc exposure. EMMA (NTW) Weathering in Arizona 250, 500, 750, (SAE J1961, Cycle 1) 1000, 1250 and
48、1500 MJ Condition for acceptance: 1250 MJ EMMA (NTW) exposure. Test acceptance criteria: The panel surface when viewed without magnification shall not exhibit coating delamination, cracking, checking, or blistering. In addition, the color expressed as units of the Yellowness Index (YI) specified in
49、ASTM D 1925 (see para 3.6.1) shall not exceed a value of + 8.00 at the end of the exposure period. The panel shall pass adhesion according to ASTM D 3359, Method B, 13 cm2of 3M 898-2 tape, figure 4b or better. The panel shall exhibit less than 7% increase in Haze per ASTM D 1003. Yellowness index and haze measurements shall be taken at three identically spaced locations along the long axis of the panel. Record and report the results of the adhesion test the individual haze and yell
